INTRODUCTION

As concrete is considered to be composite material mixed by mortar and coarse aggregate, the
former acts as matrix of binder material and the later becomes the rigid filler material. For
normal weight concrete (NWC), since the coarse aggregate possesses a larger value of E value,
therefore it behaves as the major supporting material. The mortar, on other hand, can only be
treated as a medium for stress transfer.

For lightweight aggregate concrete (LWAC), however, the aggregate becomes the minor
supporting part since it normally possesses a smaller E value. Fractures will be found in the
aggregate portion and the concrete strength is mainly dependent on the particle and packing
strengths of coarse lightweight aggregate.

There are many advantageous qualities of lightweight concrete, such as its low density, low
thermal conductivity, reduction of dead load, fast building rate, and low haulage cost.
Lightweight concrete (LWC) has been successfully used since the ancient
Roman times and it has gained its popularity due to its lower density and
superior thermal insulation properties Compared with normal weight concrete
(NWC), LWC can significantly reduce the dead load of structural elements,
which makes it especially attractive in multi- storey buildings.
Lightweight aggregate concrete (LWAC) has been used as a construction
material for many decades. The main objective for using LWAC is normally to
reduce cost by reducing the dead load of structures. E.g. with low weight the
dimensions of the foundations in buildings can be reduced in areas with low
bearing capacities, the inertia actions are reduced in seismic regions and it
enables easier handling and transportation of precast elements.
Even with the major advantage of reduced weight and the high strength-to-
weight ratio of the material compared to conventional concrete. Other
advantages of LWAC compared to normal weight concrete are the improved
durability properties, fire resistance and the low thermal conductivity.
The major disadvantage of LWAC is the brittleness in compression at the
material level compared to normal density concrete.
Ductility of LWAC in compression plays an important part in improving the
structural ductility in heavily reinforced and post-tensioned structures. Increase
of the ductility in the compression zone in bending is possible by employing
stirrups and/or fibre reinforcement to achieve passive confinement.
OBJECTIVES:
• The following are the research objectives
• To produce light weight structural concrete by leca, and cinder for different
grades of concrete(M20,M30,M40).
• To produce light weight structural concrete by blending different light weight
aggregates such as Leca and Cinder in various proportions for different
grades of concrete(M20,M30).
• To develop optimum mix design for structural light weight concrete having
high strength with low density.
 LITERATURE REVIEW
1.M.H.Jin and et.al,2009-In order to find an innovative solution to the corrosion
problem, the author investigated on the Fiber Reinforced polymer (FRP) bars as an
alternative reinforcing material in reinforced light weight concrete beams .FRP
materials are noncorrosive in nature and they also have a high strength-to-weight ratio.
2. Michala Hubert ova and et.al, 2011- This paper described the development of
lightweight concrete using light-weight expanded clay aggregate. The objective of this
research was to evaluate durability of light-weight concrete exposed to corrosive liquids
and gases (high concentrations of sulphate,chloride ions, diesel oil and gaseous CO2
and SO2 environments).
3. N.Sivalingarao and et.al, 2011- The author investigated on usage of cinder in
cement concrete applications, which is a waste material obtained from steel
manufacturing units. The conventional aggregate concrete mix had been designed for
M20 grade concrete using ISI method. Cubes, cylinders and beams of standard size 150
x 150mm, 150 x 300mm and 100 x 100 x 50mm specimens were cast and tested after
four different curing periods. The author concluded by saying that 60 percent
replacement of conventional aggregate with cinder by volume along with cement
replaced by 10% of silica fume by weight yields the target mean strength. It worth
noted there was a slight increase in strength and other properties due to extended curing
periods and the unit weight of the cinder concrete (varying from 1980 kg /cubic meter
to 2000 kg /cubic meter) with different percentage of cinder.
3. Radhakrishna and et.al, 2011- The author investigated on re-proportioning
of light weight concrete. Concrete was prepared using cement and fly ash as
binder, sand as fine aggregate and pumice as coarse aggregate. The concrete and
constituent mortar cubes were cast and tested at different ages to determine the
compressive strength. The fracture of the concrete cubes was through the
pumice aggregate. The law of mixtures was used to compute the characteristic
strength of the aggregate. Finally the author concluded that, the usual methods
of mix design for proportioning of light weight concrete were not suitable as the
fracture would not be through the transition zone
4. F.Falde and et.al, 2011- This author investigated on behavior of lightweight
concrete containing periwinkle shells to elevated temperature. The parameters
such as compressive strength, density and bond characteristics of the concrete
matrix were measured. The results showed that the compressive strength of
concrete decreased with increase in water/cement ratio and temperature ,but
increased with increase in curing age and cement ,while the density decreased
with increase in temperature.The bond between the concrete matrixes also
decreased as the temperature increased. Finally author says, lightweight
concrete containing periwinkle shells is not recommended for use in heat-
resistant structures that will be subjected to temperature less than 300◦C.
5.Payam shafigh and et.al,2011- The aim of this research paper was to
investigate on the application of high strength lightweight concrete made with
lightweight expanded clay aggregate(LECA) in reinforcement concrete beams
using the symmetrical two-point loads test. The concrete strength and steel bar
reinforcement were two important parameters examined during the beam tests.
The author compared flexural performance of the tested beams (failure modes,
load deflection response, and ultimate moment capacity) with those of the
theoretical analysis.
6. MuyasserM.Jomaa’h 2011- the author investigated on the flexural behavior
of reinforced concrete beams produced from limestone aggregate. Six beams
with varying limestone course aggregate ratios (The percentages of
replacement of natural aggregate with limestone aggregate were 0%, 50%, and
100% take average of each 2 beams) were fabricated and tested. Data presented
include the deflection characteristics, cracking behavior, and development of
the strains in steel bars. The flexural behavior of reinforced normal weight
concrete beams were comparable to that of other lightweight concretes and the
experimental results were comparing reasonably well with the finite element
method , the results confirmed that the proposed numerical analysis method
was appropriate for estimating failure behavior for normal and lightweight RC
of beams.
7. Mathew J.Heiser and et.al, 2011- This paper summarizes a comprehensive
experimental program that investigated the bond and shear behavior of concrete
beams containing Lightweight Synthetic Particle (LSP). LSP is new concrete
additive that, when used, leads to reduced unit weight of concrete, enhances
flow ability of the fresh concrete for pumping purposes, and produces durable
concrete for freezing and thawing and deicing exposed conditions. It also
reduces the thermal conductivity (increases R-values), thus reducing the energy
required for heating and cooling. The use of these specially formulated
particles, in combination with normal weight aggregates, could reduce the unit
weight of concrete by 10 to 20%, ranging from 19210 to 2080 kg/m3,
depending on the amount of LSP used in concrete mixture. The results indicated
that bond and shear behavior of beams with LSP additive was similar to the
behavior of beams made with normal weight concrete.
8. Clinker BhasarS.Mohammed and et.al, 2012- The aim of this research
paper was to investigate on the rapid chloride permeability test on
lightweight concrete produced from oil palm clinker aggregates. Oil palm
clinker is obtained from by-product of palm oil milling. The author says
utilizing oil palm clinker in concrete production not only solves the
problem of disposing this solid waste but also help to converse natural
resources. The parameter of investigation included rapid chloride
permeability test for a period of 7 days, 28 days, and 90 days.3 oil palm
clinker concrete specimens of 100 X 50 mm cylinders were cast and tested.
The chloride permeability values of oil palm clinker concrete were
compared to ASTM C1202 criteria. The result from this study showed that
the chloride permeability value of oil palm clinker concrete to be used as
aggregate in production of durable structural lightweight concrete.
SUMMARY:
Many researchers have focused on light weight concrete. Generally, from
the literatures light weight concrete has been producing by replacing
coarse aggregates by any one type of light weighted aggregates such as
expanded clay aggregates, cinder, pumice, periwinkle shells, LECA,
synthetic particles, periwinkle shells, oil palm clinker aggregates,
etc...,this has yielded good results in decreasing the dead load of the
concrete.
Researches on light weight structural concrete produced by blending
various types of aggregates are not far concentrated. Variation in
aggregates type may help us to achieve the required density with high
strength. Some of the aggregates which could be used are LECA, agilite,
cinder and also use of GGBS will help the cause. Here, due the non-
availability of agilite we are using cinder and LECA as a light weight
aggregate.
MATERIALS & METHODOLOGIES

CONCRETE:
Concrete, in construction, structural material consisting of a hard, chemically
inert particle substance, known as aggregate (usually sand and gravel), that is
bonded together by cement and water.
Concrete is characterized by the type of aggregate or cement used, by
specific qualities it manifests, or by the methods used to produce it. In
ordinary structural concrete, the character of the concrete is largely
determined by water-cement ratio. The lower the water content, all else being
equal, the stronger the concrete. The mixture must have just enough water to
ensure that each aggregate particle is completely surrounded by the cement
paste, that the spaces between the aggregate are filled, and that the concrete
is liquid enough to be poured and spread effectively.
Another durability factor is the amount of cement in relation to the aggregate
(expressed as a three-part ratio-cement to fine aggregate to coarse aggregate).
Where especially strong concrete is needed, there will be relatively less
aggregate
 TYPES OF CONCRETE
• Modern concrete
• High strength concrete
• Stamped concrete
• High performance concrete
• Light weight concrete
• Ultra-high-performance concrete
• Self consolidating concrete
• Vacuum concrete
• Shotcrete
• Limecrete
• Pervious concrete
 LIGHT WEIGHT CONCRETE

Light Weight Concrete Cube.

Concrete of substantially lower density than that made from gravel or crushed
stone, usually made with light weight aggregate.

The light weight aggregates used are usually expanded shale, clay, or slate
materials that have been fired in a rotary kiln to give them a porous structure,
similar to volcanic rock. In some mixes air cooled blast furnace slag is also used.
USES OF LIGHT-WEIGHT CONCRETE

The main reason is to reduce the overall load or weight of the entire concrete
structure, which then allows the structural designer to reduce the size of the
columns, footings and other load bearing elements . Structural light weight
concrete mixes can be designed to achieve similar compressive strengths as
normal weight concrete. They also have the same durability and mechanical
characteristics as regular weight concrete.
Light weight aggregates require wetting prior to use to achieve a high degree
of saturation. If the aggregates aren’t fully saturated they have a tendency to
float towards the surface of the mix after it has been placed. Due to higher
moisture content of light weight concrete, drying times are typically longer
than regular concrete.
Structural light weight concrete has been used for bridge decks, piers and
beams, slabs and wall elements in concrete and steel buildings, parking
structures, tilt up walls, topping slabs and composite slabs on metal decking.
 ADVANTAGES

• Higher seismic (Earthquake) Resistance. In lower densities concrete can

actually absorb shock. LWC is often used in ballistic tests because of this
ability. Hammer blows can be absorbed without fracturing the concrete.
• Lower water permeability. Greatly reduced due to the diffusion of closed
cells which prevents sponging. Also reduces the problems caused by rusting
rebar by eliminating the problem at it s source.
• More sound absorption. The transmission of sound is inversely related to
the number of air/solid interfaces. LWC has a high number of these
interfaces, thus more sound is absorbed.
Decreased Dead load. Less mass is required to support additional weight.
Structural reinforcement can be less demanding
WHY LIGHT WEIGHT CONCRETE IS IMPORTANT FOR
A COUNTRY LIKE INDIA?
India is the second largest growing country in terms of population. According
to 2012, India population is around 1.22 billion. As population is growing the
demands for basic needs of human beings are also increasing. Agriculture is
the primary occupation of Indians and nowadays construction has become
secondary occupation. Since the construction activity is directly associated
with the society, it caters to the need of housing. Housing is an important
indicator of the level of country’s social process. Besides food and clothing,
man next basic need is shelter which he requires for protecting himself
against natural calamities, animals and from other fellow beings.
The demand for construction space has increased many folds with increase in
necessity of human beings .according to recent survey, the population density
in world is around 54 persons per sq km, but in India it is around 400 persons
per sq km. so, the developing country like India is having land scarcity.
Hence vertical growth is preferred than horizontal growth, since more and
more people are moving into urban areas lead to lot of land crunch.
This land crunch and load increase demands the use of light weight
structural concrete. The light weight structural concrete. Light weight
structural concrete helps in decreasing load as the density is reduced
substantially from ranges of 2400kg/cubic meter to 1800kg/cubic meter.

Light weight structural concrete is an enhanced version of concrete, with

emphasis on decrease in density of concrete. When structural concerns
require a minimum to the dead load, light weight concrete is used. It is
ideal for roof deck repairs, stair pan fill, elevated floor slabs or over lays
on existing floor decks .since it is light weighted it is ease in lifting and
carrying which is an important advantage of light weight concrete . it also
offers slower temperature transfer rates than standard concrete, resulting
in improved insulation fact.
COARSE AGGREGATES
Coarse aggregates or simply aggregate, is a broad category of coarse
particulate material used in construction.
LECA:
LECA is an acronym term for (light expanded Clay Aggregate) which is
produced in rotary kiln at about 1200 degree centigrade as shown in
figure

Light Expanded Clay Aggregate

PROPERTIES OF LECA
• LIGHTNESS.
• THERMAL INSULATION.
• SOUND INSULATION.
• FIRE RESISTANCE.
• NON-DECOMPOSABILITY.
• WATER ABSORPTION:

ADVANTAGES OF LECA
1- Lightening up to30% of dead load.
2- Self thermal & Sound Insulation
3- Appropriate Behavior in Earthquake.
4- Physical Operation:
5- Accelerating Construction, Saving time, Labor, and material:
6- Safe for Installation:
CHARACTERIZATION OF LECA
• SPECIFIC GRAVITY OF LECA = 0.51
• BULK DENSITY OF LECA
LOOSE STATE = 0.269
COMPACTED STATE = 0.285
• SIEVE ANALYSIS FOR LECA
• LECA CRUSHING TEST =41.52 %.
CINDER
• A cinder is a pyroclastic material. Cinders are extrusive igneous rocks.
Cinders are similar to pumice, which has so many cavities and is such
low-density that it can float on water. Cinder is typically brown, black,
or red depending on its chemical content. A more modern name for
cinder is Scoria.
CHARACTERISTICS OF CINDER
• Uncemented
• Vitric
• Having bubble-like cavities, called vesicles
• Measuring not less than 2.0 millimeters in at least one dimension
• Apparent specific gravity between 1.0 and 2.0
• Typical cinders are red or black in color.
• Contain numerous gas bubbles "frozen" into place as magma
exploded into the air and then cooled quickly
CHARACTERIZATION OF
CINDER

TESTS CONDUCTED ON MATERIALS

• SPECIFIC GRAVITY OF COARSE AGGREGATE = 1.51
• AGGREGATE CRUSHING TEST = 33.0 %.
 TESTS ON
CEMENT
In the present work, zuari cement of 43 grade conforming to IS: 12269-
1987 has been used. PROPERTIES OF CEMET

Sl No. Properties Values obtained Requirement as per

IS:12269-1987

1 Fineness 2.5% Not more than 10 %

2 Soundness 3 mm Not more than 10 mm

3 Setting Time Initial 35 mins Not less than 30 mins

Final 420 mins Not more than 600 mins

4 Compressive 3 days 38 N/mm2 Not less than 27 N/mm2

strength
7 days 52 N/mm2 Not less than 37 N/mm2

28 days 68 N/mm2 Not less than 53 N/mm2

5 Standard consistency 30 % ------------------

6 Specific gravity 3.15 ------------------

 CLEAR RIVER
SAND
Sieve analysis: The results of sieve analysis conducted as per the
specifications of IS383:1970 are given below.
IS sieve Weight retained(gm) Cumulative weight Cumulative % weight cumulative percent
size(mm) retained(gm) retained(gm) passing.

4.75 75.2 75.2 2.506 97.494

2.36 103 178.2 6.173 93.827

1.18 1084.8 1263 36.16 63.84

600µ 681 1944 64.8 35.2

300µ 708 2652 88.4 11.6

150µ 266 2918 97.26 2.74

pan 82 3000 100 0

M20 GRADE (7 DAYS)
NORMAL CONCRETE
COMPRESSIV AVERAGE
SL.NO WEIGHT AVERAGE AREA LOAD E STRESS COMPRESSIV
(kg) WEIGHT (mm2) (KN) (N/mm2) E STRESS
(kg) (N/mm2)
01. 8.58 22500 510 22.67
02. 8.6 8.576 22500 490.5 21.8 22.16
03. 8.55 22500 495 22.02

M30 GRADE (7 DAYS)

NORMAL CONCRETE

COMPRESSIV AVERAGE
SL.NO WEIGHT AVERAGE AREA LOAD E STRESS COMPRESSIV
(kg) WEIGHT (mm2) (KN) (N/mm2) E STRESS
(kg) (N/mm2)

01. 8.654 22500 707 31.43

02. 8.600 8.624 22500 686.7 30.52 30.93

03. 8.620 22500 694.54 30.86
M20 GRADE (28 DAYS)
NORMAL CONCRETE
COMPRESSIVE AVERAGE
SL.NO WEIGHT AVERAGE AREA LOAD STRESS COMPRESSIVE
(kg) WEIGHT (mm2) (KN) (N/mm2) STRESS (N/mm2)
(kg)
01. 8.664 22500 882.9 39.24
02. 8.192 22500 833.85 37.06
8.418 38.07
03. 8.400 22500 853.47 37.93

M30 GRADE (28 DAYS)

NORMAL CONCRETE
COMPRESSIVE AVERAGE
SL.NO WEIGHT AVERAGE AREA LOAD STRESS COMPRESSIVE
(kg) WEIGHT (mm2) (KN) (N/mm2) STRESS (N/mm2)
(kg)
01. 8.468 22500 981 43.6
02. 8.818 22500 1030 45.78
8.595 45.78
03. 8.500 22500 1079.1 47.96
LIGHT WEIGHT
CONCRETE
LECA MAIN PROPORTION(7 DAYS)
PROPORTIONS 100 90 80 70 60 50
AVERAGE WEIGHT 5.158 5.32 5.5 5.64 6.01 6.11
AVERAGE STRESS 14.03 14.93 15.24 15.5 15.6 15.80

6.2 16
6.11 15.8
6 6.01 15.6

AVG COMP STRESS,N/mm2

15.5 15.5
5.8 15.24
5.64 15 14.93
5.6
AVG WEIGHT

5.5
5.4 14.5
5.32
5.2 5.158 14 14.03
5
13.5
4.8
13
4.6 50 60 70 80 90 100
50 60 70 80 90 100
PROPORTION
PROPORTIONS

16
15.8
15.6
AVG COMP STRESS N/mm2

15.5 15.5
15.24
15 14.93
14.5

14 14.03

13.5

13
5 5.2 5.4 5.6 5.8 6 6.2
AVG WEIGHT